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#Post#: 29--------------------------------------------------
Tank Bolt Replacement Walkthrough
By: Rusty Shovel Date: December 24, 2013, 2:04 pm
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The Enduro 690 has a known issue with it's tank bolts. I wonder
if this has been addressed in 2014?
Either way, here's a great video walkthrough describing the
preventive replacement of these troublesome bolts:
HTML http://www.youtube.com/watch?feature=player_detailpage&v=DOBVgYVZJw4#t=2
HTML http://www.youtube.com/watch?feature=player_detailpage&v=DOBVgYVZJw4#t=2
HTML http://youtu.be/DOBVgYVZJw4
#Post#: 166--------------------------------------------------
Re: Tank Bolt Replacement Walkthrough
By: seabeegt Date: February 3, 2014, 10:13 am
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Cool! Thanks for the 411 bro. Where's a good site to order them
replacement bolts? ???
#Post#: 172--------------------------------------------------
Re: Tank Bolt Replacement Walkthrough
By: Rusty Shovel Date: February 4, 2014, 6:59 am
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[quote author=seabeegt link=topic=22.msg166#msg166
date=1391443998]
Cool! Thanks for the 411 bro. Where's a good site to order them
replacement bolts? ???
[/quote]
Sorry, I should've provided a link. Rally Raid sells em:
HTML http://www.rally-raidproducts.co.uk
HTML http://www.rally-raidproducts.co.uk
Upper Tank Bolts:
HTML http://www.rally-raidproducts.co.uk/KTM-690-Enduro-R-SMC/performance-upgrades/ktm-690-subframe-tank-mounting-bolts
HTML http://www.rally-raidproducts.co.uk/KTM-690-Enduro-R-SMC/performance-upgrades/ktm-690-subframe-tank-mounting-bolts
HTML http://www.rally-raidproducts.co.uk/image/cache/data/sib%20bolts-250x250.jpg
Lower Tank Mount:
HTML http://www.rally-raidproducts.co.uk/ktm-690-lower-tank-bolt-repair-kit
HTML http://www.rally-raidproducts.co.uk/ktm-690-lower-tank-bolt-repair-kit
HTML http://www.rally-raidproducts.co.uk/image/cache/data/LOWER%20TANK%20MOUNT-500x500.jpg
Kinda expensive, but if you're about go RTW or ride the TAT,
this preventive measure might make sense for you.
#Post#: 232--------------------------------------------------
Re: Tank Bolt Replacement Walkthrough
By: coarsegoldkid Date: February 7, 2014, 1:35 pm
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I think you can get them stateside too.
The bottom one can be problematic to extract. I used my
pneumatic wrench as directed to loosen the bolts. The right
side went well. The left side broke the bolt inside the
threaded sleeve. However since all you really have to do is
remove one bolt and then tap out the sleeve through the opposite
side all is not lost.
The replacement set up is just a sleeve as in no threads and one
long bolt. The sleeve required a slight wiggle/push to fit
between the frame members when bringing the tank downward in
place. The stock upper bolt comes right out.
The kit requires that you dig into the innards a bit more.
Removal of the stock air box is required. All of this stuff is
required removal for the valve check anyway. So I would just
wait until that task comes around. I didn't because I was going
to be carrying luggage in rugged terrain sooner than checking
the valves. While I was doing this task I had lifted the tank
to gain access to the rear shock so some of what I say may or
may not be required for the subframe mod. So if you must lift
the tank the top bolts must be in place to pivot the tank up and
secure the tank with a tye down or other method.
Begin by removing airbox cover. You may need a new filter by
now anyway. There are screws on either side of the air box that
holds it to the chassis. They will need to be removed. I also
removed the front screw on the left side and not the right side
for some reason. Both may be better.
Now loosen the airbox manifoild clamp to FI body as much as you
feel needed. I think I had one thread holding the clamp
together.
Now lift the airbox with a firm, like you mean it pull , to get
the rubber manifold to part company with the FI body.
Easy enough to remove the stock upper bolt. Access to screw in
the 6mm bolt from the kit now presents itself.
You'll be done in minutes. Pop the manifold back on, tighten it
all up. Find the screw you kicked away and finish the airbox
installation.
When done smile at your bike. Have a beer.
#Post#: 655--------------------------------------------------
Re: Tank Bolt Replacement Walkthrough
By: seabeegt Date: March 31, 2014, 6:44 am
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Lol. I like the tutorial write up. Add some pictures and it'd be
bulletproof 8)
#Post#: 778--------------------------------------------------
Re: Tank Bolt Replacement Walkthrough
By: coarsegoldkid Date: April 13, 2014, 2:57 pm
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I've discovered a downside to this mod for, at least, me. Upon
close inspection between my bide and unmodified 690 the RR upper
bolt does not allow the side panel to rest flush with the tank.
6 or 7 times now my boot top has hooked under the side panel.
I can assure you that when it happens move your foot it strikes
panic because your foot cannot move freely. I've already popped
a plastic rivet out from the construction of the my right SIDI
Crossfires while forcing my leg free from under the panel. This
week I'll look into what needs to be done to correct the
situation. I suspect it will require some lathe and milling
work. Your mileage may vary.
April 15 2014
I'm having the stock upper tank bolt modified to mimic the
"under compression design" of the RR part yet be low profile so
the side cover doesn't give me problems. I should know soon if
this works out.
April 20 2014
My fix worked just fine. The threaded nipple on the stock part
was cut off. The barrel of the part was drilled and tapped for
8mm with just enough 6mm remaining. While I was at it I
discovered that the nut welded to the frame was no longer
welded. Now re-welded. Bye the way KTM orange and Rustoleum
Orange with primer in the can is almost an exact match.
#Post#: 3257--------------------------------------------------
Re: Tank Bolt Replacement Walkthrough
By: Milesofsmiles Date: November 13, 2015, 9:13 pm
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I just did tank bolt replacement using Perun Moto bolt
replacement kit. Good stuff and Nikola gets it out the door
promptly. 2014 bikes still have this issue.
Remove air box, battery, all plastic, loosen top bolts, use an
impact gun on left side bottom torq bolt, remove bottom bolt
completely, unhook gas line by battery then lift tank up from
rear. Keep lofted using tie downs to handlebars. Remove rubber
grommets on tank bottom, install new grommets and stainless
tube, lower tank down into place. You may need to file the
stainless tube to fit. Install new bolts and torq to 10nm. Now,
replace top bolts using loctite blue. Tighten to 15nm. Oh don't
forget to remove exhaust bolts on top and where it fits into
exhaust pipe. Put exhaust bolts back in when finished to 25nm.
It's a complete pain in the arse but worth the worry free
results.
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